ELECTRICAL SYSTEM

Specifications .......................................................................................... 3 1
Location of Components ..................................................................... 3 2
Harness A.................................................................................................. 3 4
Harness B.................................................................................................. 3 8 3
Harness C.................................................................................................. 3 10
Description ............................................................................................... 3 12
Console Box ............................................................................................. 3 12
Major Components ................................................................................... 3 15
Lamp Bulb Specifications .......................................................................... 3 18
Removal and Installation ...................................................................... 3 19
Console Box ............................................................................................. 3 19
Disassembly and Reassembly ............................................................ 3 20
Console Box ............................................................................................. 3 20
Components in Console Box .................................................................... 3 21
Combination Meter ................................................................................... 3 22
Sub-Meter ................................................................................................. 3 23
Batteries ................................................................................................... 3 26
Troubleshooting ...................................................................................... 3 27
Starter System .......................................................................................... 3 27
Gauges ..................................................................................................... 3 27
Lighting System ........................................................................................ 3 28
Alarm Unit ................................................................................................. 3 28
Batteries ................................................................................................... 3 29
Electrical System Schematic .............................................................. 3 31
 ELECTRICAL SYSTEM

Specifications

Truck Model
DP100 DP115 DP135 DP150
Item
Model nomenclature No. of batteries 95E41R 2

Battery Voltage V 12

Capacity Ah 80

Transmission shift lever Electric

Console box With OK monitor

Automatic transmission controller Electronic Control Unit (ECU)

Starter switch Anti-restart type

Lamps See Lamp Bulb Specifications.

3-1
ELECTRICAL SYSTEM

Location of Components

Front combination light

Harnass A

Right side

Seat frame
Heater cable

To air heater
relay

Engine
Left side

To battery relay
To engine coolant
temperature gauge unit

Harness C

Rear combination light

Harness B
210316

For the components to which harnesses A, B and C are connected, see the pages which follow.

CAUTION
Clamp the harnesses away from moving parts
or sharp edges. Repair a frayed harnesses with
vinyl tape.

3-2
 ELECTRICAL SYSTEM

Memo

3-3
ELECTRICAL SYSTEM

Harness A (located under the seat frame) Part 1

2
13
1 3

6 21
4
1
16

12 8
5 23

10

12 9
11
17
18

19

20

15

22

14

14

See page 3-6.

14
210317

3-4
 ELECTRICAL SYSTEM

1. Console box
2. Sub-meter
3. Steering column
4. Horn switch
5. Transmission shift lever
6. Turn signal switch
7. Stop lamp switch
8. RH front combination lamp
9. RH high beam
10. LH front combination lamp
11. LH high beam
12. Diode
13. Ground point
14. To harness B
15. To transmission harness
16. Junction connector
17. RH working lamp (option)
18. LH working lamp (option)
19. Cab power supply (option)
20. Front revolving light (option)
21. High beam (option)
22. Air conditioner/car heater power supply
(option)
23. Option terminal

3-5
ELECTRICAL SYSTEM

Harness A (located under the seat frame) Part 2

4 7
5 8

1 2 3

11

10

210318

3-6
 ELECTRICAL SYSTEM

1. ECU
2. Relay for battery relay
3. Relay for air dryer
4. F signal relay
5. R signal relay
6. Battery fuse
7. Fuse holder A
8. Fuse holder B
9. Speedometer power supply (option)
10. Speedometer signal (option)
11. Option terminal

3-7
ELECTRICAL SYSTEM

Harness B (located at the left of engine compartment)

16
8
2
9 6
10

7
12
15

11

14 13

210319

3-8
 ELECTRICAL SYSTEM

1. To harness A
2. To harness C
3. Glow plug
4. Electronic horn
5. Lining wear detection switch
6. Fuel tank unit
7. Battery relay
8. M5 terminal
9. Battery side terminal
10. Frame side terminal
11. Battery
12. Starter relay
13. Alternator
14. Engine coolant temperature gauge unit
15. Ground point
16. Earphone switch (option)

3-9
ELECTRICAL SYSTEM

Harness C (located at the right of engine compartment)

1
2

4
5

12

7 11

13

14

10 9

210320

3-10
 ELECTRICAL SYSTEM

1. To harness B
2 Low air pressure switch
3. Air dryer
4. Air pressure gauge unit
5. Engine stop control timer
6. Engine stop solenoid
7. Oil bypass alarm switch
8. Engine oil pressure switch
9. RH rear combination lamp
10. LH rear combination lamp
11. Ground point
12. Air cleaner dust indicator (option)
13. Working and license plate lamp (option)
14. Back-up buzzer (option)

3-11
ELECTRICAL SYSTEM

Description

Console Box 1 5 4 3
1. Engine coolant temperature gauge
2. Travel speed select switch
3. Fuel gauge
4. Service hourmeter
5. OK monitor
6. Starter switch
7. Lighting switch 7
8. Fuse box
6
8
2

207464

OK Monitor

1 2 3 4 5 6 7 8 9

207465
Function

No. Indicator light OFF ON or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
6 Glow plug indicator light Heating completed Heating
7 Turn signal indicator light Turn signal OFF Turn signal ON
8 Engine coolant level indicator light Normal Low Option
9 Headlamp beam indicator light Low High Option
How to check indicator light bulbs
The bulbs are normal if the indicator lights 1, 2, 3 and 8 come ON when the starter switch key is turned to
(ON) position. (The indicator lights will go OFF when the engine starts.)

3-12
 ELECTRICAL SYSTEM

Components

9
6

3
2

1
7

207176

1. Power relay 4. Glow plug relay 7. Starter switch

2. Power relay 5. Glow plug timer 8. Fuses
3. Turn signal relay 6. Lighting switch 9. Travel speed select switch

Spare Terminals
The spare terminal cord extends from the fuse box in the
console box. (Another spare terminal is in the chassis-side
main harness.)

Color code Lg (light green)

Removing the console box rear panel will permit you to

gain access to this spare terminal which is taped to the
harness protector.

Spare terminal 207209

3-13
ELECTRICAL SYSTEM

Side Instrument Panels

7 8 5
1

2 4 6

3
210321

1. Working lamp switches (option) 5. Brake air pressure gauge

2. Working lamp indicators (option) 6. Battery switch
3. Windshield wiper switches (option) 7. Powershift transmission oil temperature gauge
4. Brake lining wear indicator 8. Speedometer (option)

3-14
 ELECTRICAL SYSTEM

Major Components
Electronic Control Unit (ECU)

Failure indicator lights

LED (green)

LED (red)

Rear (mounting) face

205509

The Electronic Control Unit (ECU) has a built-in 1-
chip microcomputer. This computer processes signals
from the travel speed sensor for actuating the 2-speed
automatic transmission.
The ECU has self-diagnostic failure indicator lights
which come on when any problem occurs in the
electrical system, thereby allowing the operator to
locate the problem. It has the following fail-safe
systems so that failure of power, control circuit, or
other components will not endanger the operator.
NOTE
The failure indicator lights are located on the rear
(mounting) face of the ECU. This makes it
necessary to remove the ECU from the truck to
observe these lights.

Fail-safe Systems

Failure Function

Solenoid output signal circuit Turns OFF the power line and causes an indicator light to
open come on when the solenoid output signal circuit is open.

Travel speed sensor circuit Allows the truck to run at the present travel speed but
open causes an indicator light to come on.

Failure Indicator Light Flashing Patterns

Failure Flashing pattern

Travel speed sensor circuit

open

2-speed automatic transmission

control circuit open 204697

NOTE: The failure indicator lights come ON and go OFF as shown below:

ON

OFF 204668

3-15
ELECTRICAL SYSTEM

Starter Switch (Anti-restart Type) running) to help prevent damage to the starter pinion or
flywheel ring gear. The (ON) position of the switch is
This switch has a built-in mechanical lockout. This
for energizing the glow plugs.
lockout restrains the key from turning to (START)
position from (ON) position (as when the engine is

(OFF)
(ON)

B M
(START)

203561A
Connection Chart

Terminal B M S

Component Fuse box, batteries, Fuse box, engine stop Transmission shift
Key alternator, glow plugs control timer, glow lever, glow plug timer
position plug timer and relay

(OFF) {
(ON) { {
(START) { { {

Lighting Switch

OFF 1st 2nd Knob position

8 8 Stroke
(0.3) (0.3) [Unit: mm (in.)]

206481
Connection Chart

Terminal B T H P
Tail lamps, license
Component Batteries plate lamp (option), Headlamps Front combination
Knob (fuses) instrument panel lamps
position lamp

(OFF)
1st position { { {
2nd position { { { {

3-16
 ELECTRICAL SYSTEM

Fuse Box

Symbol Capacity Circuit

A 10 A Transmission shift lever

B 10 A Instrument panel lamp,

A
turn signals
B
C C 10 A Spare terminal
D
E D 15 A Lamps
F
E 10 A Horn
G
H F 10 A Spare
J

G 10 A Transmission controller,
vacuum buzzer, stop lamps
H 10 A Back-up lamps
J 15 A Spare

101441F

Optional fuses

Fuse Capacity Circuit Fuse

Battery fuse 15 A holder B
Fuse
15 A Working lamps holder A
Fuse holder A 10 A Revolving lamp
10 A Air dryer relay
15 A Air conditioner Battery fuse
5A Car heater
Fuse holder B
20 A Windshield wiper
210322
10 A Cab

3-17
ELECTRICAL SYSTEM

Lamp Bulb Specifications

Item Bulb
Quantity Color of
of bulbs lens For 24V Remarks
Type of lamp system Schematic drawing

Headlamps 2 Frosted 60W 60/60W

(option)

Turn signal lamps 2 Amber 25W

Standard
Combination (mounted on
lamps (front) overhead guard)
Clearance lamps 2 Frosted 12W

Stop and tail lamps 2 Red 10W/25W

Combination Turn signal lamps 2 Amber 25W

lamps (rear)

Back-up lamps 2 Frosted 25W

Working lamps (front) 2 Frosted 60W/60W Option

Working lamps (rear) 2 Frosted 60W/60W Option

License plate lamp 1 Frosted 12W Option

Instrument panel lamps 2 Frosted 3W

For combination
meter

OK monitor indicator lamps 5 Frosted 3W

207466
3-18
 ELECTRICAL SYSTEM

Removal and Installation

Console Box
Removal

6 5

5
4

1
207539A

Start by: 5. Disconnect the electrical wires at connectors, and

(a) Turn off the starter switch, and disconnect the remove transmission shift lever and turn signal
negative (grounding) cable from the battery. lever 5.
(b) Remove nut and washer on steering wheel, and 6. Remove bolts on console box assembly 6, and
remove the steering wheel. remove the console box assembly.

Suggestions for Removal Installation

1. Disconnect the electrical wires at connectors 1. To install, follow the reverse of removal sequence.
2. Remove screws on cover 2 using a flat-tip
screwdriver, and remove the cover.
3. Remove screws on cover (U-RE) 3, and remove the
cover.
4. Remove screws on cover (U-FR) 4, and remove the
cover.

3-19
ELECTRICAL SYSTEM

Disassembly and Reassembly

Console Box
Disassembly

3 207175

Suggestions for Disassembly Reassembly

1. Remove two screws 1 securing the cover. (Use a To reassemble the console box, follow the reverse of
flat-tip screwdriver.) disassembly sequence.
2. Remove six screws 2 and separate the front and
rear panels.
3. Remove four screws 3 securing the instrument
panel.

NOTE
To replace the instrument panel bulbs, remove screws
2 and 3.

3-20
 ELECTRICAL SYSTEM

Components in Console Box

Disassembly

10
7

2
8

9
1

207558

Sequence
1. Harness 6. Glow plug timer
2. Power relay 7. Lighting switch
3. Power relay 8. Starter switch
4. Turn signal relay 9. Fuses
5. Glow plug relay 10. Travel speed select switch

Reassembly
To reassemble the console box, follow the reverse of
disassembly sequence.

3-21
ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3

8
9
206480

Sequence
1. Instrument panel 6. Meter case
2. Dial 7. Printed circuit plate
3. Engine coolant temperature gauge 8. Bulb
4. Service hourmeter 9. Socket
5. Fuel gauge

CAUTION Bulb replacement

Be careful not to damage the printed circuit For bulb replacement, remove the socket from the
plate when disassembling the combination printed circuit plate by turning it counterclockwise.
meter. For configuration of the indicator lights, refer to OK
Monitor.

Reassembly
To reassemble the combination meter, follow the
reverse of disassembly sequence.

3-22
 ELECTRICAL SYSTEM

Sub-Meter
Disassembly

7
4

3 9
10

11 2

12

210323

Sequence
1. Disconnect the harness at connectors 1.
2. Remove three bolts 2 that hold the side instrument
panel, and remove the instrument panel from the seat
frame.
3. Remove four screws 3 and separate panel 4 from cover
5.
4. Remove the following components:
6. Brake air pressure gauge
7. Battery switch
8. Brake lining wear indicator
9. Powershift transmission temperature gauge
10. Low air pressure buzzer
11. Power relay
12. Brake lining wear buzzer

3-23
ELECTRICAL SYSTEM

Reassembly
Follow the reverse of disassembly sequence.

NOTE
Connect the air pressure gauge harness to the correct
terminal.

(Green/red)
Air pressure
(Black) gauge terminal
(Green)

(Blue)

To brake lining
wear indicator

To battery switch

To low air
To power relay pressure buzzer

To brake lining
wear buzzer

210324

3-24
 ELECTRICAL SYSTEM

Precautions for installing other parts

1. Engine stop solenoid installation

(1) Before installing the solenoid, push the plunger all the 0 0
L=26-1.5 mm (1.02 -0.063 in.)
way into it to make sure that the plunger stroke
coincides with the standard value.

0 0
Stroke L 26 1.6 mm (1.02 0.063 in.)

Note: Record the measured value of plunger stroke.

210325

(2) After installing the solenoid, connect a lamp (or tester)

and power supply to it. V
Testa
(3) Energize the solenoid to see if the lamp is lit. (Check
voltage when the tester is used.) Lamp

NOTE
When testing the solenoid -
(1) Do not energize any longer than 5 seconds. DC24V

(2) Do not energize any more than 5 times.

AUX 210326

3-25
ELECTRICAL SYSTEM

Batteries

1. Electrolyte specific gravity (S.G.) reading and battery condition

Electrolyte S.G. reading

Battery condition Adjustment
at 20C (68F)

1.280 to 1.265 Battery is fully or well Check each cell for S.G.
charged.

1.260 to 1.225 Battery is half charged. Recharge the battery. Make sure there is neither faulty
component, short-circuited cord nor corroded connection in
the system.

1.220 or lower Battery is discharged. Recharge the battery. If difference in S.G. among the cell is
large, adjust the S.G. during recharging.

When S.G. difference A cell with a low S.G. Recharge until voltage and S.G. stabilize and have remained
among cells is more is in shorted condition. constant for at least 2 hours.
than 0.040 Some electrolyte has During recharging, adjust the S.G. to anywhere between
been lost. Too much 1.280 and 1.265.
electrolyte, or water in If difference in S.G. among the cells is more than 0.040 and
electrolyte, too. a low S.G. is found in certain cells only, replace the battery.

2. Relationship between electrolyte specific (3) During charging, adjust the charging current to
gravity and charging rate prevent the battery electrolyte temperature from
rising beyond 45C (113F).
To check the battery for charging, take hydrometer
readings on its electrolyte: the battery may be deemed (4) When connecting the cables to the battery, begin
to be fully charged if the readings are between 1.280 with the cable for the positive (+) terminal. When
and 1.265 at normal temperature. The tendency of the disconnecting them from the battery, begin with the
charging system can be told from the way the cable for the negative (-) terminal.
electrolyte level goes down to expose cell plates. If
refilling (with distilled water) is necessary every month CAUTION
or so, the system is tending to over-charge the battery.
If refilling is not required for over 3 months, it is likely Be sure to turn off the starter switch and
that the system is inadequately charging. lighting switch before disconnecting or
connecting the battery cables to prevent the
3. Precautions for battery charging
IC regulator from suffering damage.
(1) In slow-charging a dead battery, the charging
current should be about 1/10 the capacity of the
battery to be charged.
(2) In quick-charging the battery, the battery capacity
in ampere should not be exceeded.

3-26
 ELECTRICAL SYSTEM

Troubleshooting
Starter System
Dead or weak battery Recharge or replace.
Starter circuit defective Repair or replace.
Starter will not crank
engine Poor continuity in starter switch Replace.
Starter or starter relay defective Replace.
Transmission shift lever not in neutral Move the lever to
Starter switch position neutral position.

Turning off starter Open or short circuit Repair or replace.

switch will not stop Engine stop solenoid defective Replace or readjust.
engine Control timer defective Replace.

Gauges
Open or short circuit Repair or replace.
Will not indicate at all Gauge internally defective Replace.
Gauge unit defective Replace.

Temperature Will not indicate Wrong type of gauge or gauge unit Replace.
gauges accurately Loose terminal connection Repair.

Will indicate higher than Circuit between gauge and gauge unit Repair.
grounded
actual temperature
Gauge internally defective Replace.

Open or short circuit Repair or replace.

Will not indicate at all Gauge internally defective Replace.
Gauge unit defective Replace.

Will not indicate Gauge or gauge unit not of the type Replace.
called for
accurately
Loose terminal connection Repair.

Fuel gauge Circuit between gauge and gauge unit Repair.

Will indicate Full grounded
regardless of fuel level
in tank Gauge internally defective Replace.
Gauge unit defective Replace.

Circuit between gauge and gauge unit Repair.

Will indicate Empty open or short
regardless of fuel level
in tank Gauge unit defective Replace.
Gauge internally defective Replace.

Will not indicate Open or short circuit Repair or replace.

(even if air pressure is Gauge defective Replace.
acting on gauge unit) Gauge unit defective Replace.
Air pressure
gauge
Indication will not Circuit between gauge and gauge unit Repair.
return to 0 (when air grounded
pressure is 0 kPa Gauge defective Replace.
(0 kgf/cm2) [0 psi]) Gauge unit defective Replace.

3-27
ELECTRICAL SYSTEM

Lighting System
Dead or weak battery Recharge or replace.
Fuses blown out Check and replace.
Will not light Open or short circuit Repair or replace.
Poor grounding Clean ground spot and re-make
connection.
Bulbs burnt out Replace.
Lamps
general
Dead or weak battery Check and recharge.
Burned contact points in switches Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.

Light switch defective Replace.

Headlamps Will not light
Bulbs burnt out Replace.

Bulbs burnt out Replace.

Will not flash
Turn signal relay defective Replace.

Turn signal relay defective Replace.

Will not go out
Turn signal switch defective Replace.
Turn signal
lamps Wrong wattage of bulbs Replace.
Will flash too slow Weak battery Recharge or replace.
Turn signal relay detective Replace.

Wrong wattage of bulbs Replace.

Will flash too fast
Turn signal relay defective Replace.

Back-up lamps Back-up lamp switch defective Correct if improperly installed:

replace if internally defective.
will not lights
Bulbs burnt out Replace.
Other lamps
License plate
Lighting switch defective Replace.
lamp will not
lights Bulb burnt out Replace.

Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not give blast
of sound Horn switch defective Repair or replace.
Horn defective Replace.
Horn Horn button defective Replace.

Will give abnorm- Horn switch defective Replace.

al blast of sound Horn defective Replace.

3-28
 ELECTRICAL SYSTEM

Batteries

Alternator belt slipping Readjust.

* Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.

* Regulator
Regulated voltage setting too low Readjust.
Tends to run down rapidly
* Batteries
Not enough electrolyte or wrong proportion of Refill and check
acid to water specific gravity: 1.280
Battery cell plates deteriorated Replace.
(possibly internal short-circuit)
Terminal connections loose Clean and retighten.

* Wiring
Open or loose connection between starter switch Repair.
and regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator

* Wiring
Circuit between regulator IC and F terminals Repair.
shorted or miswired
Poor grounding of regulator F terminal Repair.
Tends to get overcharged
* Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Readjust.

3-29
ELECTRICAL SYSTEM

Memo

3-30
 ELECTRICAL SYSTEM

Electrical System Schematic

3-31